Protective cushion cover for an electronic device

ABSTRACT

A protective case for an electronic device may have two layers: an inner cushion cover that surrounds a portion of the electronic device, and an outer rigid shell that surround part of the cushion cover. The outer shell has side walls that engage and hold the cushion cover on the electronic device. The cushion cover has reduced thickness portions so that the side walls are embedded in the cushion cover and provide a protective case having a substantially smooth exterior. The cushion cover is capable of absorbing shocks from impacts on the rigid outer shell. Coring on the inner portion of the cushion cover provides additional softness and the ability of the cushion cover to absorb shocks while using a higher density material, which is able to conform to the electronic device.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation application of U.S. application Ser.No. 14/598,196, filed Jan. 15, 2015, which is a continuation applicationof U.S. application Ser. No. 12/687,390, filed Jan. 14, 2010, whichclaims domestic priority of Provisional Patent Application Ser. No.61/236,065, filed Aug. 21, 2009. Each of these references isincorporated herein by reference thereto.

BACKGROUND OF THE INVENTION

Numerous different types of electronic devices currently exist forcommunication, entertainment and other purposes. These include cellphones, MP3 players, video players, smartphones, communication devices,such as walkie-talkies, navigation devices, such as GPS devices, andother types of electronic devices, such as various types of computers,including laptop computers, hand-held computers, ultra-mobile computersand tablet computers. These devices often include touch screens,interactive panels including, but not limited to, capacitive coupledinterfaces, keyboards, scroll wheels, tilt switches, push buttonswitches, and other interactive controls. Due to the sensitive nature ofthese electronic devices, it is desirable to provide protection forthese devices.

SUMMARY OF THE DISCLOSURE

An embodiment of the present disclosure may therefore include aprotective case for an electronic device and having an outer shell and acushion cover. The outer shell may include a back portion and at leasttwo side walls. The back portion may have a proximal edge, a distaledge, a first lateral edge and a second lateral edge that is oppositethe first lateral edge. The side walls of the outer shell may beconnected to, and extend from, respective edges of the back portion. Atleast two of the side walls may be positioned to engage the cushioncover on respective side surfaces of the cushion cover. The outer shellmay be formed of a plastic material that resiliently bends sufficientlyduring installation on the electronic device to engage the cushion coveragainst the electronic device. Each of the side walls may be configuredto generate a force on a different respective one of the respective sidesurfaces of the cushion cover when the cushion cover and outer shell areinstalled on the electronic device.

The cushion cover may be formed of an elastomeric material and includereduced thickness portions, raised impact portions and coring. Theelastomeric material may be form-fitted to cover a portion of theelectronic device. The cushion cover may have a density and elasticitythat cause the cushion cover to conform to the electronic device. Thereduced thickness portions may be disposed in predetermined areas of thecushion cover, such that the two or more of side walls of the outershell disposed in, and engaged with, the reduced thickness portions suchthat the force generated by the two or more side walls is coupledthrough the reduced thickness portions to the electronic device. Theraised impact portions may each protrude between two of the side wallsat a perimeter of the outer shell. The coring may include openingsformed in an interior surface of the cushion cover and may extend intothe cushion cover. The openings may allow portions of the cushion coversurrounding the openings to compress substantially perpendicular to aplane of the openings while expanding substantially parallel to theplane of the openings to absorb impacts.

A disclosed method of manufacturing a protective case for an electronicdevice may include forming a cushion cover, forming a rigid outer shell,forming a raised impact portion of the cushion cover, and formingopenings in a surface of the cushion cover. The cushion cover may beformed of an elastomeric material and structured to cover a portion ofthe electronic device. The cushion cover may have a density andelasticity that cause the cushion cover to conform to the electronicdevice when installed thereon. The cushion cover may have a cushion backand a cushion side wall that extends in a first direction about aperimeter of the cushion back. The rigid outer shell may be formed froma material having a higher density and lower elasticity than theelastomeric material of the cushion cover. The outer shell may have ashell back corresponding to the cushion back, and a plurality ofseparated shell side walls. The shell back may be formed to include aproximal end, a distal end opposite the proximal end, a first lateralend, and a second lateral end opposite the first lateral end, where eachof the shell side walls may be connected to and extend from at least twoof the ends of the shell back. At least the shell side walls of theouter shell may have rigidity sufficient to substantially maintainposition relative to the shell back while pressing portions of thecushion side wall against the electronic device, when the electronicdevice is at least partially covered by the cushion cover. At least oneof the shell side walls may have a thickness that permits resilientcompliance during installation of the electronic device into theprotective case, the shell back corresponding to the cushion back.

The raised impact portion may be formed in the cushion side wall. Theraised impact portion may be disposed at a region of the cushion sidewall that corresponds to a perimeter separation between the shell sidewalls. The plurality of openings may be formed in and distributed acrossa portion of an interior surface of at least the cushion back of thecushion cover. The openings reduce density of the interior surface thatis adjacent to the electronic device when the protective case covers atleast a portion of the electronic device.

In another disclosed embodiment a protective case for an electronicdevice may include a cushion cover and a rigid outer shell. The cushioncover may be formed of an elastomeric material, and structured to covera portion of the electronic device. The cushion cover may have a densityand elasticity that cause the cushion cover to conform to the electronicdevice when installed thereon. The cushion cover may have a cushionback, and a cushion side wall that extends in a first direction from thecushion back about a perimeter of the cushion back. The rigid outershell may be formed of a material having a higher density and lowerelasticity than the elastomeric material of the cushion cover. The outershell may have a shell back corresponding to the cushion back, and aplurality of separated shell side walls. The shell back may include aproximal end, a distal end opposite the proximal end, a first lateralend, and a second lateral end opposite the first lateral end. Theplurality of shell side walls may be connected to and extend from atleast two of the ends of the shell back, at least the shell side wallsof the outer shell having rigidity sufficient to substantially maintainposition relative to the shell back while pressing portions of thecushion side wall against the electronic device when the electronicdevice is at least partially covered by the cushion cover. At least oneof the shell side walls may have a thickness that permits resilientcompliance during installation of the electronic device into theprotective case, and the shell back may correspond to the cushion back.

The cushion side wall may include a raised impact portion disposed at aregion of the cushion side wall that may correspond to a perimeterseparation between the shell side walls. The cushion cover may alsoinclude a plurality of openings in and distributed across a portion ofan interior surface of at least the cushion back. These openings reducethe density of the interior surface that is adjacent to the electronicdevice when the protective case covers at least a portion of theelectronic device.

In one exemplary embodiment, a protective case for an electronic deviceis provided. The case includes a rigid outer shell having a back portionhaving a proximal edge, a distal edge, a first lateral edge, and asecond lateral edge that is opposite the first lateral edge, and atleast two arms connected to and extending from respective edges of theback portion, each arm formed from a resilient plastic material. Thecase also includes a cushion cover formed from an elastomeric materialconfigured to cover a portion of the electronic device, the cushioncover having an interior surface configured to contact an outer surfaceof the electronic device and an exterior surface opposite the interiorsurface. The cushion cover includes at least two reduced thicknessportions disposed in predetermined areas of the cushion cover, whereineach of the arms is configured to engage the surface of a correspondingreduced thickness portion to securely hold the reduced thicknessportions of the cushion cover to the electronic device, raised impactareas positioned at corners of the cushion cover and having a thicknessgreater than a thickness of the reduced thickness portions, the raisedimpact areas configured to substantially absorb an impact with a hardsurface, and coring comprising recesses formed in the interior surfaceof the cushion to allow portions of the cushion cover surrounding theopenings to compress substantially perpendicular to a plane of theopenings while expanding substantially parallel to the plane of theopenings to absorb impacts.

In one exemplary embodiment, a protective case for an electronic deviceis provided. The case includes an outer shell formed from athermoplastic material and a cushion cover formed from an elastomericmaterial configured to cover a portion of the electronic device. Theouter shell includes a back portion having a proximal edge, a distaledge, a first lateral edge, and a second lateral edge that is oppositethe first lateral edge, and at least two arms connected to and extendingfrom respective edges of the back portion. The cushion cover has aninterior surface configured to contact an outer surface of theelectronic device, an exterior surface opposite the interior surface,and at least two lateral edges. The cushion cover includes at least tworeduced thickness portions disposed in predetermined areas of thecushion cover, wherein each of the arms is configured to engage thesurface of a corresponding reduced thickness portion to securely holdthe reduced thickness portions of the cushion cover to the electronicdevice, raised impact areas having a thickness greater than a thicknessof the reduced thickness portions, the raised impact areas configured tosubstantially absorb an impact with a hard surface, and coringcomprising recesses formed on the interior surface of the lateral edgesof the cushion cover to allow portions of the cushion cover surroundingthe openings to compress substantially perpendicular to a plane of theopenings while expanding substantially parallel to the plane of theopenings to absorb impacts.

In one exemplary embodiment, a protective case for an electronic deviceis provided. The case includes an outer shell including a back portionhaving a proximal edge, a distal edge, a first lateral edge, and asecond lateral edge that is opposite the first lateral edge, and atleast two arms connected to and extending from respective edges of theback portion, each arm including a lip or pointed hook. The case alsoincludes a cushion cover formed from an elastomeric material configuredto cover a portion of the electronic device, the cushion cover having aninterior surface configured to contact an outer surface of theelectronic device and an exterior surface opposite the interior surface.The cushion cover includes at least two reduced thickness portionsdisposed in predetermined areas of the cushion cover, wherein each ofthe arms and each of the lips or pointed hooks is configured to engagethe surface of a corresponding reduced thickness portion to securelyhold the reduced thickness portions of the cushion cover to theelectronic device, raised impact areas having a thickness greater than athickness of the reduced thickness portions, the raised impact areasconfigured to substantially absorb an impact with a hard surface, andcoring comprising recesses formed on the interior surface of the cushioncover to allow portions of the cushion cover surrounding the openings tocompress substantially perpendicular to a plane of the openings whileexpanding substantially parallel to the plane of the openings to absorbimpacts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view of an embodiment of a protectivecovering system for an electronic device.

FIG. 2 is an exploded schematic perspective view of the embodimentillustrated in FIG. 1.

FIG. 3 is a partially exploded schematic perspective view of theembodiment that is illustrated in FIG. 1.

FIG. 4 is a side exploded view of the embodiment of FIG. 1.

FIG. 5 is a schematic front view of the embodiment of the rigid outershell illustrated in FIG. 1.

FIG. 6 is a schematic front view of the embodiment of the cushion coverillustrated in FIG. 1.

FIG. 7 is a schematic perspective view of another embodiment of aprotective case.

FIG. 8 is a schematic perspective view of another embodiment of aprotective case.

FIG. 9 is an assembly view of the embodiment of FIG. 8.

FIG. 10 is an assembly view of the embodiment of FIGS. 8 and 9.

FIG. 11 is a side assembly view of the embodiment of FIGS. 8 through 10.

FIG. 12 is a front view of the rigid outer shell of the embodiment ofFIG. 8.

FIG. 13 is a front view of the cushion cover of the embodiment of FIG.8.

FIG. 14 is an assembly view of another embodiment of a protective case.

FIG. 15 is a front view of an embodiment of a die cut plug.

FIG. 16 is a side view of the embodiment of the die cut plug of FIG. 15.

FIG. 17 is a front view of another embodiment of a die cut plug.

FIG. 18 is a side view of the embodiment of the die cut plug of FIG. 17.

FIG. 19 is a perspective view of an embodiment of a ruled blade.

FIG. 20 is a front view of another embodiment of a die cut plug.

FIG. 21 is a side view of the embodiment of the die cut plug illustratedin FIG. 20.

FIG. 22 is a perspective view of another embodiment of a ruled blade.

FIG. 23 is a perspective view of the protective covering system of FIG.1 with a die cut plug, as shown in FIG. 15, located in the cushion coverof the protective covering system.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 1 is a schematic perspective view of one embodiment of a protectivecase 100 that utilizes a protective cushion cover 104 that is surroundedby a rigid outer shell 102 to provide protection to an electronic device106. The electronic device 106 can be any type of an electronic deviceincluding various types of MP3 players, video players, cell phones,smartphones, satellite phones, walkie-talkies, GPS navigational devices,telematics devices, pagers, monitors, personal data assistants, bar codescanners, as well as various types of computers including portablecomputers, laptop computers, handheld computers, ultra-mobile computers,tablet computers and various hybrid devices that combine two or more ofthese functions. In addition, these devices may operate with only atouch screen interface or only a keyboard and display or other type ofmanual input, and are not limited to devices that include keyboards orbuttons as well as a touch screen.

As shown in FIG. 1, the rigid outer shell 102 has a plurality of curvedflexible arms 108, 110, 112, 114 (FIG. 2). The rigid outer shell is aninjected molded shell that is constructed from polycarbonate, nylon,polycarbonate and nylon blend, a polycarbonate methyl methacrylatebutadiene styrene or other similar material that can bend withoutbreaking. The rigid outer shell 102 is formed so that the curvedflexible arms 108-114 have sculpted edges without sharp corners thatintersect with and hold the cushion cover 104 on the electronic device106. The rigid outer shell 102 is sufficiently thin to allow the curvedflexible arms 108-114 which allows the electronic device 106 that iscovered with the cushion cover 104, to be inserted into the rigid outershell 102. In that regard, the curved flexible arms 108-114 havesufficient elasticity to allow sufficient flexion of the curved flexiblearms 108-114 to insert the electronic device 106 and cushion cover 104into the rigid outer shell 102 without breaking the curved flexible arms108-114, which holds the cushion cover 104 securely on the outer surfaceof the electronic device 106. Hence, the curved flexible arms 108-114secure and hold the cushion cover 104 on the outer surface of theelectronic device 106.

Pre-shaping of the cushion cover 104, illustrated in FIG. 1, makes thecushion cover form-fitting around the electronic device 106. The cushioncover 104 is made from a soft, pliable material, such as an elastomericmaterial, that is capable of stretching sufficiently to allow theelectronic device 106 to slide easily into and be removed from thecushion cover 104. The cushion cover 104 has sufficient elasticity toallow the protective cover to conform closely to the electronic device106 after the cushion cover 104 has been stretched over the electronicdevice 106. The cushion cover 104 can be made of a variety of thermosetmaterials, such as synthetic rubber, silicon, urethane and othermaterials that are capable of stretching sufficiently to allow theelectronic device 104 to slide into the front opening 105 of the cushioncover 104 while maintaining the form-fitting shape of the cushion cover104. The density and elasticity of the cushion cover 104, as well as thepre-forming of the cushion cover 104 to fit the shape of electronicdevice 106, allows the material of the cushion cover 104 to both stretchand recover so that the cushion cover fits tightly on the electronicdevice 106.

The raised portions of the cushion cover 104 that are illustrated inFIG. 1, including the raised impact areas 116-122, as well as the edgeportions 124, 126, 128, 130, prevent an impact with a hard surface frombeing transmitted directly to the electronic device 106. The material ofthe cushion cover 104 is sufficiently soft and sufficiently thick tosubstantially absorb and prevent an impact with a hard surface fromfully compressing the cushion cover 104. In that regard, the raisedimpact areas 116-122 are located on surfaces where an impact with a hardsurface is likely to occur that could cause damage to the electronicdevice 106, such as the corners and the area surrounding the frontportion of the electronic device 106.

FIG. 2 is an exploded view of the embodiment of FIG. 1. As shown in FIG.2, a slim profile for the protective case 100 is desirable to allow easeof use of the electronic device 106 and allow the electronic device 106to be conveniently stored in pockets, purses and on belt clips whileoccupying minimal space. Further, it is desirable to have the outersurface of the protective case 100 made of a material that can easilyslide in and out of confined spaces, such as pockets, purses, etc.Typical soft covers, such as cushion cover 106, are made from siliconeor other elastomeric materials that do not slide easily on surfaces, butrather, tend to cling to surfaces.

The protective case 100, illustrated in FIG. 2, has a slim profile as aresult of the reduced thickness portions, such as reduced thicknessportion 134, 136, 138, 140 (FIG. 6), 142. The curved flexible arms 108,110, 112, 114 fit within the reduced thickness portions 134, 136,138,142 (FIG. 6) respectively, and reduce the overall size and profileof the protective case 100. Back 132 fits within the recessed thicknessportion 140 on the back surface of the cushion cover 104. The back 132of the outer shell 102 may be slightly thicker than the curved flexiblearms 108-114 which provides greater stability for the protective case100. In that regard, the rigid outer shell 102 provides structuralstability for the protective case 100 that protects the electronicdevice 106 in addition to holding the cushion cover 104 in place on theelectronic device 106. For example, the rigid outer shell 102 absorbsand disperses impacts to the cushion cover 104 across the contactsurfaces between the rigid outer shell 102 and the cushion cover 104. Inthis fashion, a large portion of the cushion cover 104 is utilized toabsorb shocks resulting from impacts to the rigid outer shell 102.Accordingly, the structural stability that is added by the rigid outershell 102 maintains the cushion cover 104 in close contact with theelectronic device 106, as well as absorbing and spreading impacts acrossthe contact surfaces between the rigid outer shell 102 and the cushioncover 104.

Another beneficial advantage that the rigid outer shell 102 provides isthat the density of the cushion cover 104 can be reduced which increasesthe softness of cushion cover 104 which, in turn, increases the abilityof the cushion cover 104 to absorb shocks and impacts. As the density ofthe cushion cover 104 is increased, the conformability of the cushioncover 104 to the electronic device 106 increases. Accordingly, a higherdensity cushion cover 104 conforms better to the electronic device 106than a cushion cover that is less dense. The elastomeric material, suchas silicone, can be formed with different densities to create thedesired amount of conformability. Of course, if the cushion cover 104 ismade from a less dense material, the cushion cover 104 may have lessconformability to the electronic device 106 so that the edge portions,such as edge portions 124-130 become separated from the electronicdevice 106, and gaps form between the edge portions 124-130 and theelectronic device 106, especially over time. The disadvantage, however,with the use of a denser elastomeric material as a cushion cover 104 isthat the denser material is not as soft as less dense material, and itdoes not absorb shocks as well as less dense material. By using a rigidouter shell 102, less dense material, that is better able to absorbshocks than denser materials, can be used since the rigid outer shell102 securely holds the cushion cover 104 on a plurality of sides of theelectronic device 106. In this manner, the absorbability of shocks bythe cushion cover 104 is increased.

The rigid outer shell 102 can be made from a material, such aspolycarbonate or other thermoplastic materials that have a smoothsurface, which allows the protective case 100 to be easily placed in andremoved from pockets, or other tight areas, without binding. Further,the rigid material of the outer shell 102 can be mixed with afluorescing material so that the protective case 100 can be located moreeasily in light-restricted areas.

FIG. 3 is a schematic assembly view illustrating the rigid outer shell102 and the electronic device 106 disposed within the cushion cover 104.As illustrated in FIG. 3, the curved flexible arms 108, 110, 112 fit inthe reduced thickness portions 134, 136, 138, respectively. Theremaining portions of the cushion cover 104 comprise thicker portionsfor impact protection for direct hits on cushion cover 104. Thethickness of the cushion cover 104 in the thicker areas substantiallymatches the level of the curved flexible arms that are disposed in thereduced thickness portions. For example, when the rigid outer shell 102is placed on the cushion cover 104, the curved flexible arm 110 isdisposed within the reduced thickness portion 136. The outside surfaceof the curved flexible arm 110 substantially matches the outside surfaceof the edge portion 126 and the surrounding thicker portions of thecushion cover 104. The same is true with respect to the curved flexiblearm 108 and the reduced thickness portion 134, the curved flexible arm112 and the reduced thickness portion 138 and the curved flexible arm114 and the reduced thickness portion 142. Hence, edge portion 124 isapproximately on the same level with the outer surface of the curvedflexible arm 108 around the edges of the curved flexible arm 108.Similarly, the edge portion 128 is at approximately the same level asthe outer surface of the curved flexible arm 112. Further, edge portion130 is approximately at the same level as the curved flexible arm 114.In this manner, a consistent outer surface of the protective case 100 isprovided, so that the protective case 100 does not get caught on objectsand can be easily placed in and removed from confined areas, such aspockets, purses, etc.

As illustrated in FIGS. 3-7, the protective case 100 is a two-part case,in which the cushion cover 104 is partially surrounded by the rigidouter shell 102. A primary purpose of the rigid outer shell 102 is toprotect the electronic device 106 from a hit or blow from a sharpobject, such as the corner of a desk, a rock, a countertop edge, a stairedge or other sharp object, and spread that blow or hit over the surfacearea of the rigid outer shell 102. The cushion cover 104 then functionsto absorb the shock of the hit or blow, so that the shock from the hitor blow is not transferred directly to the electronic device 106. Hence,if the assembly of the protective case 100 and electronic device 106 isdropped on a sharp object, and the curved flexible arms 108-114 or back132 are impacted by the sharp object, the rigid outer shell 102 absorbsthe impact and spreads that impact over the surface of the rigid outershell 102 and transmits the shockwaves from the impact to the cushioncover 104, rather than to the electronic device 106.

FIG. 4 is a side exploded view illustrating the rigid outer shell 102,the cushion cover 104, and the electronic device 106. As shown in FIG.4, the curved flexible arms 108, 112 fit over the top and bottom,respectively, of the cushion cover 104. Curved flexible arm 110 fitswithin the reduced thickness area 136. During assembly, the electronicdevice 106 is first placed within the cushion cover 104. The assembly ofthe electronic device 106 and cushion cover 104 are then inserted withinthe rigid outer shell 102. Again, the curved flexible arms 108-114 arecapable of flexing and bending sufficiently to allow the assembledelectronic device 106 and cushion cover 104 to be inserted within therigid outer shell 102.

FIG. 5 is a front view of the rigid outer shell 102. As shown in FIG. 5,each of the curved flexible arms 108-114 is connected to the back 132 ofthe rigid outer shell 102. The curved flexible arms 108-114 have asculptured shape that provides a smooth outer surface for the user. Thecurved sculptured shape of the curved flexible arms 108-114 provides fora slim profile and smooth gripping surface without sharp edges extendingfrom the rigid outer shell 102.

FIG. 6 is a front view of the cushion cover 106. As illustrated in FIG.6, the reduced thickness portions 134, 136, 138, 140, 142 are surroundedby the raised impact areas 116, 118, 146, 148. The cushion cover 106also has a front opening 144 that allows the electronic device 106 to beinserted in, and removed from, the cushion cover 106. In the embodimentof FIG. 6, the back portion of the cushion cover 106 that intersects theback 132 of the outer rigid shell 102 is a reduced thickness portion.The reduced thickness portion 140 of the cushion cover 106 can haveraised impact areas that can protrude through openings in the back 132of the rigid outer shell 102 to provide an additional raised impact areaon the back of the protective case 100.

FIG. 7 is a schematic perspective view of another embodiment of aprotective case 700. As shown in FIG. 7, the rigid shell 702 has anopening 710, which allows access to a raised pad 712. The raised pad 712is part of the cushion cover 704 which interacts with controls on theelectronic device 706. Hence, the rigid shell 702 can be placed in areasthat are aligned with interactive controls on the electronic device 706and still allow interaction with those controls on the electronic device706 by providing openings in rigid shell 702. A similar raised pad 708is shown on the cushion cover 704 that is not surrounded by the rigidshell 702.

FIG. 8 is a schematic perspective view of another embodiment of aprotective case 800. As shown in FIG. 8, a protective case 800 surroundsan electronic device 806, such as a smartphone. The protective case 800comprises a rigid outer shell 802 that surrounds a cushion cover 804.The rigid outer shell 802 is tightly secured to the upper and lowerportions of the electronic device 806 over the cushion cover 804. Thecushion cover 804 surrounds the electronic device 806 and has a frontopening 809 that exposes the front portion of the electronic device 806.

FIG. 9 is an assembly view of the protective case 800 and the electronicdevice 806. As shown in FIG. 9, the rigid outer shell 802 has a curvedflexible arm 808 on an upper portion of the rigid outer shell 802 and acurved flexible arm 810 on a bottom portion of the rigid outer shell802. A curved back portion 811 connects the curved flexible arm 808 andcurved flexible arm 810 to form the rigid outer shell 802 as a singlestructure. Curved flexible arm 808 has a pointed hook 812 on one side ofthe curved flexible arm 808 and a pointed hook 814 on the other side ofthe curved flexible arm 808. Similarly, pointed hook 816 and pointedhook 818 are on opposite sides of the curved flexible arm 810.

FIG. 9 also illustrates the cushion cover 804. Cushion cover 804 has areduced thickness portion 822 that is engaged by the curved flexible arm808 of the rigid outer shell 802. Similarly, reduced thickness portion824 is engaged by the curved flexible arm 810 of the rigid outer shell802. The pointed hooks 812-820 engage the surface of the reducedthickness portions 822, 824 adjacent the surface of the electronicdevice 806. In this manner, the rigid outer shell 802 securely holds thereduced thickness portions 822, 824 of the cushion cover 804 securely tothe electronic device 806. Since the pointed hooks 812-820 are able tograsp and hold the reduced thickness portions 822, 824 and securely holdthe cushion cover 804 to the electronic device 806, most of the face ofthe electronic device 806 can be exposed through the front opening inthe protective case 800.

Alternatively, the pointed hooks 812-820 can engage the upper edge 834of the electronic device 806 and securely hold the rigid outer shell 802to the electronic device 806. Similarly, pointed hooks 816, 820 canengage the lower edge 836 of the electronic device 806 and securely holdthe bottom portion of the rigid outer shell 802 to the electronic device806. Since these hooks are able to grasp the electronic device 806 atthe upper edge 834 and the lower edge 836 in this alternativeembodiment, most of the face of the electronic device 806 is alsoexposed through the front opening in protective case 800.

As also shown in FIG. 9, the cushion cover 804 is made from a softmaterial as described above and form fit to fit the outer surface of theelectronic device 806. The cushion cover 804 is stretchable and can bemade of a variety of thermoset materials, such as synthetic rubber,silicone, urethane or other materials that are capable of stretchingsufficiently to allow the electronic device 806 to slide into the frontopening of the cushion cover 804. The elasticity of the cushion cover issufficient to allow the protective cover to easily conform to theelectronic device 806 and allow the electronic device 806 to tightly fitwithin the protective cover 102.

As further illustrated in FIG. 9, lateral edges 830, 832 are thicker onthe sides of cushion cover 804 in comparison to the reduced thicknessportions 822, 824. The top surface of the cushion cover 804 that adjoinsthe front face of the electronic device 808 is beveled, so that theheight of the cushion cover 804 adjacent the front face of theelectronic device 806 nearly matches the height of the face of theelectronic device 806. The low profile of the cushion cover 804 adjacentthe front face of the electronic device 806 allows easy useraccessibility for entering data, including texting and typing of data.Lateral edge 830 includes coring 826, while lateral edge 832 has asimilar coring 828 (not shown). Coring 826, 828 allows a denser materialto be used as a cushion cover 804 to provide a high degree of elasticityand formability of the cushion cover 804 to the electronic device 806while providing enhanced cushioning and shock absorbing on the lateraledges 830, 832, as explained in more detail below. Also, the densermaterial has better durability and elasticity than less dense material.The rigid outer shell 802 provides a smooth, curved surface that doesnot substantially cover the face of the electronic device 806 and allowsa user substantially full access to the front surface of the electronicdevice 806 while securely connecting both the cushion cover 804 and therigid outer shell 802 to the electronic device 806. As disclosed above,the rigid outer shell can be constructed of polycarbonate, nylon, ABS,or the like, and alloys thereof, or other similar material that can bendwithout breaking. This material can be mixed with a fluorescent materialso that the rigid outer shell 802 can be located in dim lightconditions.

In order to achieve the results of providing a protective covering thatis thin and conforms well to the electronic device, while havingthicker, softer portions in impact areas, such as corners and lateralside edges, it would appear that two different types of material wouldbe required. The use of two different types of materials, that areeither welded together or layered, would substantially increase the costof a protective cover because of the increased manufacturing costsresulting from the complexity of the manufacturing processes for formingprotective covers that are made from more than one material, in additionto the added cost of using two different materials.

Alternatively, the embodiments disclosed herein provide the cushioningthat would otherwise by provided by a softer, thicker material, whileutilizing a single, denser material. The cushion cover 104, 804 is madefrom a material that has a density that allows the protective cover toconform well to the electronic device 106, 806, while also providingthicker, raised portions in impact areas, such as the corners, thatsimultaneously prevent an impact with a hard surface from beingtransmitted directly to the electronic device 106, 806, as a result ofthe cushion cover 108, 804 being compressed in the impact area, as wellas being sufficiently soft to absorb and prevent the transfer of energythrough the cushion cover 104, 804 to the electronic device 106, 806. Inthis manner, denser materials can provide protection that is equivalentto the protection provided by thicker, less dense materials to protectagainst the transfer of an impact directly to the electronic deviceresulting from compression of the protective cover material. In thatregard, thinner, denser materials are more advantageous for a protectivecover, since they provide a slimmer profile than thicker, less densematerials that provide equivalent impact protection.

The coring 826, 828 includes a plurality of recesses. Between eachadjacent recess is a rib. Hence, a plurality of recesses and ribs areprovided along the lateral edges 830, 832. The recesses form the ribswhich provide a softer, more flexible area in the corner portions andother impact zones that absorb the shock of impact. Of course, anyportion of the protective cushion cover 804 that needs impact protectioncan utilize coring, and the coring is not limited to being disposed onthe lateral edges 830, 832. The ribs provide support for the lateraledges 830, 832, while the recesses and ribs allow the lateral edges 830,832 to compact and absorb energy from impacts. In this fashion, thelateral edges 830, 832 are softer, even though the material used for theenlarged corner portions is a denser material. The recesses allowcompression of the ribs into the recess portions, so as to absorb shockand energy from impacts. The size of the ribs, with respect to the sizeof the recesses, can be varied to vary the amount of compression thatoccurs so that shocks occurring in drop situations are absorbed.

FIG. 10 is an assembly view illustrating the manner in which the rigidouter shell 802 is mounted on the cushion cover 804, which is mounted onthe electronic device 806. As shown in FIG. 10, the cushion cover hasthe reduced thickness portions 822, 824 that are engaged by the curvedflexible arms 808, 810, respectively. The curved flexible arms 808, 810surround and clamp onto the reduced thickness portions 822, 824. Thecurved flexible arms 808, 810 are secured to the cushion cover 804 andelectronic device 806. Forces created by the pointed hooks 812-818 onthe cushion cover 804 assist in holding the cushion cover 804 to theelectronic device 806. The force generated by the curved flexible arms808, 810 on the reduced thickness portions 822, 824 is a result of theelasticity of the curved arms 808, 810.

FIG. 11 is a side assembly view of the embodiment of FIGS. 8-10. Asshown in FIG. 11, the electronic device 806 fits within the cushioncover 804. The cushion cover 804 fits within the rigid outer shell 802.The curved flexible arms 808, 810 have pointed hooks, such as pointedhooks 814, 818 that engage the cushion cover 804.

FIG. 12 is a front view of the rigid outer shell 802. As shown in FIG.12, curved flexible arm 808 includes a lip 838, which engages andattaches to the cushion cover 804. Similarly, curved flexible arm 810has a lip 840 that engages and attaches to the cushion cover 804. Inthis manner, the pointed hooks 812, 814, 816, 818, as well as the lips838, 840, assist in securing both the rigid outer shell 802 and thecushion cover 804 to the electronic device 806.

FIG. 13 is a front view of the cushion cover 804 of the embodiment ofFIG. 8. As shown in FIG. 13, the reduced thickness portions 822, 824 aredisposed between the lateral edges 830, 832. Again, the lateral edges830, 832 are not covered by the rigid outer shell 802 and provide agripping surface for the user of the protective case.

FIG. 14 is an assembly view of another embodiment of a protective case1400. As shown in FIG. 14, the protective case includes a cushion cover1404 that fits within the rigid outer shell 1402. The electronic device1406 fits within the cushion cover 1404. As illustrated in FIG. 14, thelateral edges 1408, 1410 do not include any coring. These lateral edgesmay be slightly thicker than the remaining portion of the cushion cover1404 to provide additional cushioning. In addition, the cushion cover1404 may be made of a softer material to add additional cushioning.

FIG. 15 is a front view of a die cut plug 1500. Die cut plug 1500 is cutfrom the cushion cover and provides an opening in the cushion cover toaccess an electrical plug, such as a headphone plug. The die cut plug1500 has a nipple 1502 that is a generally cylindrical shape and extendsoutwardly from the surface of the die cut plug 1500. The nipple 1502 isdisposed on the die cut plug 1500 to be inserted in an opening, such asa headphone opening in the handheld electronic device 106. Strain reliefhole 1504 and strain relief hole 1506 are also cut in the cushion cover104 adjacent the cuts for the die cut plug 1500. The strain relief holes1504, 1506 provide a round, smooth area, which intersects the cuts madefor the die cut plug 1500 to prevent the cushion cover 104 from ripping.The additional surface area and smooth transition of the die cut toround strain relief holes 1504, 1506, assists in preventing the cushioncover 104 from ripping at the end of each die cut of the die cut plug1500.

As shown in FIG. 16, nipple 1502 forms a part of the cushion cover thatis cut to form the die cut plug 1500. The nipple 1502 is formed when thecushion cover 104 is formed. Nipple 1502 is located on the cushion cover104 so that the nipple 1502 can be inserted in an opening in theelectronic device 106, such as a headphone jack. The nipple 1502 has adepth and width that allows the nipple to easily slip into the headphonejack opening in the electronic device 106 and hold the die cut plug 1500in place.

FIG. 17 is a front view of a die cut plug 1700. Die cut plug 1700 has anipple 1702 that has a wedge 1708 removed from the nipple 1702. In someelectronic devices 106, mechanical arms are present in an opening, suchas a headphone jack that sense the presence of a headphone and switchthe electrical signals from the speaker to the headphone jack. Thesemechanical sensors may be disposed along one side of the headphone jackin the electronic device 106. The wedge 1708 is removed from the nipple1702 in the location where the nipple 1702 would otherwise engage themechanical sensors in the electronic device 106 that sense a plug in theheadphone jack. The removal of the wedge 1708 from the nipple 1702allows the nipple 1702 to be inserted in the headphone jack in theelectronic device 106 without activating the mechanical switches in theheadphone jack. FIG. 17 also illustrates the strain relief hole 1704,1706 that assist in preventing rips and tears in the cushion cover 104.

FIG. 18 is a side view of the die cut plug 1700. As shown in FIG. 18,the nipple 1702 extends a predetermined distance and has a predeterminedsize to fit within an opening in the electronic device 106. The nipple1702 holes the die cut plugs in position on the electronic device 106.

FIG. 19 is a perspective view of a ruled blade 1900 that is used to cutthe cushion cover 104 to create the die cut plug 1500, illustrated inFIG. 15. The ruled blade 1900 is bent into the desired shape to form thedie cut plug 1500 and has a curved portion 1902. The ruled blade 1900 isalso bent to form the strain relief hole cutter portion 1904 and thestrain relief hole cutter portion 1906. In operation, the ruled blade1900 has a sharp edge that is pressed against the cushion cover 104 andcuts the cushion cover 104 in the shape of the ruled blade 1900. Byprocess creates the die cut plug 1500 that is illustrated in FIG. 15.Since a ruled blade is used to cut the cushion cover, little or nomaterial is removed from the cushion cover so that when the die cut plug1500 and the other die cut plugs disclosed herein are in a closedposition, there is no gap between the die cut plug and the cushioncover, which stops the entry of dust and dirt into the interior portionof the cushion cover. Die cut plugs that are cut by a laser leave a gap,which allows water and dirt to easily enter the interior portion of thedie cut cover.

FIG. 20 is a front view of another embodiment of a die cut plug 2000.Die cut plug 2000 has a rectangular shape, as illustrated in FIG. 20.Nipple 2002, as shown in FIGS. 20 and 21, extends outwardly from the diecut plug 2000. The nipple 2002 has a shape and size that fits into aport on the electronic device, such as a USB port or a proprietary port.The die cut plug 2000 has strain relief holes 2004, 2006 that reducestrain on the cushion cover so that the cushion cover does not rip whenthe die cut plug 2000 is pulled outwardly.

FIG. 22 is a perspective view of a ruled blade 2200 that can be used tocut the die cut plug 2000 in the cushion cover. The ruled blade 2200 isbent in the desired shape to form the die cut plug 2000. For example,FIG. 22 illustrates that the ruled blade 2200 is formed in a rectangularshape that has strain relief hole cutters 2202, 2204 that cut the strainrelief holes 2004, 2006 respectively. Again, the cushion cover, such ascushion cover 104, is placed in a holder, so that the ruled blade 2200can be lowered onto the cushion cover to cut the cushion cover. Theholder may be made of a material that will not substantially dull theruled blade 2200 during the cutting process.

FIG. 23 is a perspective view of one embodiment of a protective coveringsystem, such as the protective covering of FIG. 1, with a die cut plug,such as the die cut plug shown in FIG. 15, located in the cushion coverof the protective covering system. As described above, the die cut plug1500 may, in a closed state, cover a port of the electronic device 106.A nipple (not shown in FIG. 23) may engage walls of the electronicdevice port for a friction or interference fit. In an open state, thedie cut plug 1500 may bend along a strain relief, with strain reliefholes 1504 and 1506 providing a round, smooth area, which intersectscuts made for the die cut plug 1500 to prevent the cushion cover 104from ripping when the die cut plug 1500 is pulled from the closed state.

The foregoing description of the invention has been presented forpurposes of illustration and description. It is not intended to beexhaustive or to limit the invention to the precise form disclosed, andother modifications and variations may be possible in light of the aboveteachings. The embodiment was chosen and described in order to bestexplain the principles of the invention and its practical application tothereby enable others skilled in the art to best utilize the inventionin various embodiments and various modifications as are suited to theparticular use contemplated. It is intended that the appended claims beconstrued to include other alternative embodiments of the inventionexcept insofar as limited by the prior art.

What is claimed is:
 1. A protective case for an electronic device, theprotective case comprising: a rigid outer shell having: a back portionhaving a proximal edge, a distal edge, a first lateral edge, and asecond lateral edge that is opposite the first lateral edge, and atleast two arms connected to and extending from respective edges of theback portion, each arm formed from a resilient plastic material, acushion cover formed from an elastomeric material configured to cover aportion of the electronic device when the electronic device is installedin the protective case, the cushion cover having an interior surfaceconfigured to contact an outer surface of the electronic device and anexterior surface opposite the interior surface, the cushion coverincluding: at least two reduced thickness portions disposed inpredetermined areas of the cushion cover, wherein each of the arms isconfigured to engage the surface of a corresponding reduced thicknessportion to securely hold the reduced thickness portions of the cushioncover to the electronic device, raised impact areas positioned atcorners of the cushion cover and having a thickness greater than athickness of the reduced thickness portions, the raised impact areasconfigured to substantially absorb an impact with a hard surface, andcoring comprising recesses formed in the interior surface of the cushioncover to allow portions of the cushion cover surrounding the recesses tocompress substantially perpendicular to a plane of the openings whileexpanding substantially parallel to the plane of the openings to absorbimpacts.
 2. The protective case according to claim 1, wherein the armsof the rigid outer shell and the raised impact areas define a perimeterof the protective case when the electronic device is secured in theprotective case by the rigid outer shell and the cushion cover.
 3. Theprotective case according to claim 1, wherein the cushion cover furthercomprises a raised pad corresponding to a control mechanism of theelectronic device, the raised pad providing interactive access to thecontrol mechanism through the raised pad when the electronic device isinstalled in the protective case.
 4. The protective case according toclaim 3, wherein a side wall of the rigid outer shell includes anopening aligned with the raised pad, the opening permitting access tothe raised pad through the side wall opening.
 5. The protective caseaccording to claim 1, wherein the cushion cover includes at least twolateral edges, and wherein the recesses are disposed on the interiorsurface of lateral edges of the cushion cover.
 6. The protective caseaccording to claim 1, wherein an outside surface of at least one of theraised impact areas is substantially flush with an outside surface of anarm of the rigid outer shell.
 7. The protective case according to claim1, wherein each arm includes a pointed hook on one side of the arm, thehook engaging the surface of a corresponding reduced thickness portionto securely hold the reduced thickness portions of the cushion cover tothe electronic device.
 8. The protective case according to claim 1,wherein each arm includes a lip on one side of the arm, the hookengaging the surface of a corresponding reduced thickness portion tosecurely hold the reduced thickness portions of the cushion cover to theelectronic device.
 9. A protective case for an electronic device, theprotective case comprising: an outer shell formed from a thermoplasticmaterial, the outer shell including: a back portion having a proximaledge, a distal edge, a first lateral edge, and a second lateral edgethat is opposite the first lateral edge, and at least two arms eachconnected to and extending from one of the proximal edge, the distaledge, the first lateral edge, and the second lateral edge of the backportion, a cushion cover formed from an elastomeric material configuredto cover a portion of the electronic device, the cushion cover having aninterior surface configured to contact an outer surface of theelectronic device, an exterior surface opposite the interior surface,and at least two lateral edges, the cushion cover including: at leasttwo reduced thickness portions disposed in predetermined areas of thecushion cover, wherein each of the arms is configured to engage thesurface of a corresponding reduced thickness portion to securely holdthe reduced thickness portions of the cushion cover to the electronicdevice, raised impact areas having a thickness greater than a thicknessof the reduced thickness portions, the raised impact areas configured tosubstantially absorb an impact with a hard surface, and coringcomprising recesses formed on the interior surface of the lateral edgesof the cushion cover to allow portions of the cushion cover surroundingthe recesses.
 10. The protective case according to claim 9, wherein theraised impact areas are positioned at corners of the cushion cover and afront portion of the cushion cover, the raised impact areas configuredto compress substantially perpendicular to a plane of the openings whileexpanding substantially parallel to the plane of the openings to absorbimpacts and to prevent an impact with a hard surface from fullycompressing the cushion cover.
 11. The protective case according toclaim 9, wherein the arms of the outer shell and the raised impact areasdefine a perimeter of the protective case when the electronic device issecured in the protective case by the outer shell and the cushion cover.12. The protective case according to claim 11, wherein an outsidesurface of at least one of the raised impact areas is substantiallyflush with an outside surface an arm of the outer shell.
 13. Theprotective case according to claim 9, wherein the cushion cover furthercomprises a raised pad corresponding to a control mechanism of theelectronic device, the raised pad providing interactive access to thecontrol mechanism through the raised pad when the electronic device isinstalled in the protective case.
 14. The protective case according toclaim 13, wherein a side wall of the rigid outer shell includes anopening aligned with the raised pad, the opening permitting access tothe raised pad through the side wall opening.
 15. The protective caseaccording to claim 9, wherein each arm includes a pointed hook on oneside of the arm, the hook engaging the surface of a correspondingreduced thickness portion to securely hold the reduced thicknessportions of the cushion cover to the electronic device.
 16. Theprotective case according to claim 9, wherein each arm includes a lip onone side of the arm, the hook engaging the surface of a correspondingreduced thickness portion to securely hold the reduced thicknessportions of the cushion cover to the electronic device.
 17. A protectivecase for an electronic device, the protective case comprising: an outershell including: a back portion having a proximal edge, a distal edge, afirst lateral edge, and a second lateral edge that is opposite the firstlateral edge, and at least two arms connected to and extending fromrespective edges of the back portion, each arm including a lip orpointed hook, a cushion cover formed from an elastomeric materialconfigured to cover a portion of the electronic device, the cushioncover having an interior surface configured to contact an outer surfaceof the electronic device and an exterior surface opposite the interiorsurface, the cushion cover including: at least two reduced thicknessportions disposed in predetermined areas of the cushion cover, whereineach of the arms and each of the lips or pointed hooks is configured toengage the surface of one of a corresponding reduced thickness portionto securely hold the reduced thickness portions of the cushion cover tothe electronic device, impact areas having a thickness greater than athickness of the reduced thickness portions, the impact areas configuredto substantially absorb an impact with a hard surface, and coringcomprising recesses formed on the interior surface of the cushion coverto allow portions of the cushion cover surrounding the openings tocompress substantially perpendicular to a plane of the openings whileexpanding substantially parallel to the plane of the openings to absorbimpacts.
 18. The protective case according to claim 17, wherein theimpact areas are positioned at corners of the cushion cover and a frontportion of the cushion cover, the impact areas configured to prevent animpact with a hard surface from fully compressing the cushion cover. 19.The protective case according to claim 17, wherein the arms of the outershell and the impact areas define a perimeter of the protective casewhen the electronic device is secured in the protective case by theouter shell and the cushion cover.
 20. The protective case according toclaim 18, wherein an outside surface of at least one of the impactportions is substantially flush with an outside surface an arm of therigid outer shell.